SECTION 9A - SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) -SERVICING
Service Precaution
General Description
Restraint Devices
System Description
SRS Component And Wiring Location View
Component Description
SRS Control Unit
"Air Bag" Warning Lamp
SRS Coil Assembly
Air Bag Assemblies
Steering Column
Knee Bolster
Definitions
Diagnosis
Diagnostic Trouble Codes
Scan Tool Diagnostics
Use Of Special Tools
SRS Connector Body Face Views
Repairs And Inspections Required After An
Accident
Accident With Deployment-Component
Replacement And Inspections
Accident With or Without Deployment-
Component Inspection
SRS Control Unit Replacement Guidelines
Wiring Damage
SRS Connector (Plastic Body And Terminal
Metal Pin) Damage
SRS Wire Pigtail Damage
On-Vehicle Service
Service Precaution
Disable The SRS
Enabling The SRS
Handling / Installation / Diagnosis
Air Bag Assembly Handling / Shipping / Scrapping
Live (Undeployed) Air Bag Assembly
Air Bag Assembly Shipping Procedure For Live
(Undeployed) Air Bag Assemblies
Deployed Air Bag Assembly (Driver Side)
Air Bag Assembly Scrapping Procedure
Deployment Outside Vehicl e (Driver Air Bag
Assembly)
Deployment Outside Vehicle (Passenger Air Bag
Assembly)
Deployment Inside Vehicle (Vehicle Scrapping
Procedure)
Deployed Air Bag Assembly Handling
Tech2 Scan Tool
Getting Started
Service Precautions for SRS Component Service
Disabling The SRS
Enabling The SRS
Handling / Installation / Diagnosis
Inspections Requir ed After An Accident
SRS Connectors
Removal
Installation
SRS Control Unit
Service Precautions
Removal
Installation
Driver Air Bag Assembly
Service Precautions
Removal
Installation
Steering Wheel
Service Precautions
Removal
Installation
SRS Coil Assembly
Service Precautions
Removal
Installation
Steering Column
Service Precautions
Removal
Installation
Passenger Air Bag Assembly
Service Precautions
Removal
Installation
Main Data and Specifications
Fastener Tightening Specification
Special Tools
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING
SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING
SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT,
PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the
exact part number for that application. HOLDEN will call out those fasteners that require a replacement after
removal. HOLDEN will also call out the fasteners that require thread lockers or thread sealant. UNLESS
OTHERW ISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on
threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque
and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct
tighten ing sequence and specifications. Follow ing these inst ructions can help you av oid damage to parts an d
systems.
General Description
CAUTION: When fasteners are removed, always
reinstall them at the same location from which
they were removed. If a fastener needs to be
replaced, use the correct part number fastener fo
r
that application. If the correct part numbe
r
fastener is not available, a fastener of equal size
and strength (or stronger) may be used.
Fasteners th at are not reused, and those requiring
thread locking compound will be called out. The
correct torque value must be used when installing
fasteners that require it. If the above conditions
are not followed, parts or system damage could
result.
Restraint Devices
827RW006
Legent
(1) Deployed Air Bag
(2) Knee Bolster
(3) Seat Belt
The Supplemental Restraint System (SRS) helps
supplement the protection offered by the driver and
front passenger seat belts by deploying an air bag
from the center of the steering wheel and from the
front of the passenger side of the instrument panel.
The air bag deploys when the vehicle is involved in a
frontal crash of sufficient force up to 30 degrees off the
centerline of the vehicle. To further absorb the crash
energy there is a knee bolster located beneath the
instrument panel for both the driver and passenger,
and the steering column is collapsible.
827RW005
System Description
The SRS consists of the SRS control unit, the driver
air bag assembly, the SRS coil assembly , the
passenger air bag assembly and the “AIR BAG”
warning lamp in the instrument cluster. The SRS
control unit, SRS coil assembly (driver side only),
driver air bag assembly, passenger air bag assembly
and connector wire make up the deployment loops.
The function of the deployment loops is to supply
current through air bag assembly, which will cause
deployment of the air bags in the event of a frontal
crash of sufficient force, up to 30 degrees off the
centerline of the vehicle. The air bag assemblies are
only supplied enough current to deploy when the SRS
control unit detects vehicle velocity changes severe
enough to warrant deployment.
The SRS control unit contains a sensing device which
converts vehicle velocity change to an electrical signal.
The electrical signal generated is processed by the
SRS control unit and then compared to a value stored
in memory. When the generated signal exceeds the
stored value, the SRS control unit will cause current to
flow through the air bag assembly deploying the air
bags.
RTW39JMF000101
SRS Component And Wiring Location View
060R300039
Component Description
SRS Control Unit
WARNING: DURING SERVICE PROCEDURES, BE
V
ERY CAREFUL WHEN HANDLING A SRS
CONTRO L UNIT NEVER STRIKE O R JAR T HE SRS
CONTORL UNIT. NEVER POWER UP THE SRS
WHEN THE SRS CONTROL UNIT IS NOT RIGIDLY
A
TTACHED TO THE VEHICLE. ALL SRS
CONTROL UNIT AND MOUNTING BRACKET
FASTENERS MUST BE CAREFULLY TORQUED
A
ND THE ARROW MUST BE POINTED TOWARD
THE FRONT OF THE VEHICLE TO ENSURE
PROPER OPERATION OF THE SRS. THE SRS
CONTROL UNIT COULD BE ACTIVATED WHEN
POWERED WHILE NOT RIGIDLY ATTACHED TO
THE VEHICLE WHICH COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL
INJURY.
The SRS control unit is designed to perform the
following functions in the SRS:
1. Energy Reserve — The SRS control unit maintains
24–Volt Loop Reserve (24VLR) energy supply to
provide deployment energy w hen ignition voltage is
lost in a frontal crash.
2. Frontal Crash Detection — The SRS control unit
monitors vehicle velocity changes to detect frontal
crashes which are severe enough to warrant
deployment.
3. Air Bag Deployment — When a frontal crash o
f
sufficient force is detected, the SRS control unit
will cause enough current to flow through the ai
r
bag assembly to deploy the air bag.
4. Malfunction Detection — The SRS control unit
performs diagnostic monitoring of SRS electrical
components and sets a diagnostic trouble code
when a malfunction is detected.
5. Frontal Crash Recording — The SRS control unit
records information regarding SRS status during
frontal crash.
6. Malfunction Diagnosis — The SRS control unit
displays SRS diagnostic trouble codes and system
status information through the use of a scan tool.
7. Driver Notification — The SRS control unit warns
the vehicle driver of SRS malfunctions b
y
controlling the “Air Bag” warning lamp.
The SRS control unit is connected to the SRS wiring
harness by a 52–pin connector. This harness
connector uses a shorting clip across certain terminals
in the contact area. This shorting clip connects the
“AIR BAG” warning lamp to ground when the SRS
control unit harness connector is disconnected or CPA
(Connector Position Assurance) is not inserted even if
completely connected. This will cause the “AIR BAG”
warning lamp to come “ON” steady whenever the
ignition switch is at the ON or START positions with
the SRS control unit disconnected.
060R300008
Legent
(1) SRS Control Unit
(2) SRS Harness
(3) Connector Position Assurance
“Air Bag” Warning Lamp
Ignition voltage is applied to the “AIR BAG” warning
lamp when the ignition switch is at the ON or START
positions. The SRS control unit controls the lamp by
providing ground with a lamp driver. The “AIR BAG”
warning lamp is used in the SRS to do the following:
1. Verify lamp and SRS control unit operation b
y
flashing SEVEN (7) times when the ignition switch
is first turned “ON”.
2. Warn the vehicle driver of SRS electrical system
malfunctions which could potentially affect the
operation of the SRS. These malfunctions could
result in nondeployment in case of a frontal crash
or deployment for conditions less severe than
intended.
The “AIR BAG “ warning lamp is the key to driver
notification of SRS malfunctions. For proper lamp
operation, refer to the “SRS Diagnostic System
Check” in this section.
060R300007
SRS Coil Assembly
The SRS coil assembly consists of two current
carrying coils. This is attached to the steering column
and allow rotation of the steering wheel while
maintaining continuous contact of the driver
deployment loop to the driver air bag assembly.
There is a shorting clip on the yellow connector near
the base of steering column which connects the SRS
coil to the SRS wiring harness.
The shorting clip shorts to the SRS coil and driver air
bag assembly when the yellow connector is
disconnected. The circuit to the driver air bag
assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing
the steering column or other SRS components.
060R300047
Air Bag Assemblies
The air bag assembly consist of an inflatable air bag
assembly and an inflator. When the vehicle is in a
frontal crash of sufficient force.
The SRS control unit causes current flow through the
deployment loops. Current passing through the inflator
ignites the material in the air bag assembly. The gas
produced from this reaction rapidly inflates the air bag
assembly.
There is a shorting clip on the driver air bag assembly
connector which connects the SRS coil assembly. The
shorting clip shorts across the driver air bag assembly
circuits when driver air bag assembly connector is
disconnected.
The circuit to the driver air bag assembly is shorted in
this way to help prevent unwanted deployment of the
air bag when servicing the driver air bag assembly, the
steering column or other SRS components.
060R300012
There is a shorting clip on the passenger air bag
assembly connector which connects to the SRS
harness. The shorting clip shorts across the
passenger air bag assembly circuit when the
passenger air bag assembly connector is
disconnected. The circuit to the passenger air bag
assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing
the passenger air bag assembly, the instrument panel
or other SRS components.
060R300013
Steering Column
The steering column absorbs energy and is designed
to compress in a frontal crash to decrease the chance
of injury to the driver.
060R300038
Knee Bolster
The knee bolsters are used to absorb energy to
protect knees and control the forward movement of
the vehicle's front seat occupants during a frontal
crash, by limiting leg movement.
Definitions
Air Bag
An inflatable cloth cushion designed to deploy in
certain frontal crashes. It supplements the protection
offered by the seat belts by distributing the impact load
more evenly over the vehicle occupant's head and
torso.
Asynchronous
Performed in a nonperiodic fashion, (i.e., no defined
time or interval).
B+
Battery voltage, (B+) The voltage available at the
battery at the time of the indicated measurement.
With the key “ON” and the engine not running, the
system voltage will likely be between 12 and 12.5
volts. At idle, the voltage may be 14 to 16 volts. The
voltage could be as low as 10 volts during engine
cranking.
Bulb Check
The SRS control unit will cause the “AIR BAG” warning
lamp to flash seven times and then go “OFF”
whenever the ignition switch transitions to the ON
position from any other ignition switch position and no
malfunctions are detected.
“Continuous Monitoring”
Tests performed by the SRS control unit on the SRS
every 100 milliseconds while “Ignition 1” voltage is in
the normal operating voltage range at the SRS control
unit.
Data Link Connector (DLC)
Formerly “DLC” a connector which allows
communication with an external computer, such as a
scan tool.
Datum Line
A base line parallel to the plane of the underbody or
frame from which all vertical measurements originate.
Deploy
To inflate the air bag.
Deployme nt Loops
The circuits which supply current to the air bag
assemblies to deploy the air bag.
Diagnostic Trouble Code (DTC)
Formerly “Code”, a numerical designator used by the
SRS control unit to indicate specific SRS malfunctions.
Driver Current Source
A
n output of the SRS control unit which applies current
into the driver air bag assembly circuit during the
“Initiator Assembly Resistance Test”.
Driver Air Bag Assembly
An assembly located in the steering wheel hub
consisting of an inflatable bag, an inflator and an
initiator.
EEPROM
Electrically Erasable Programmable Read Only
Memory. Memory which retains its contents when
power is removed from the SRS control unit.
Ignition Cycle
The voltage at the SRS control unit “Ignition 1” inputs,
with ignition switch “ON”, is within the normal operating
voltage range for at least ten seconds before turning
ignition switch “OFF”.
Ignition 1
A battery voltage (B+) circuit which is only powered
with the ignition switch in the ON, or START positions.
Initiator
The electrical component inside the air bag assembly
which, when sufficient current flows, sets off the
chemical reaction that inflates the air bag.
“Initiator Assembly Resistance Test”
Tests performed once each ignition cycle when no
malfunctions are detected during “Turn–ON” or
“Continuous Monitoring”. This test checks for the
correct SRS control unit configuration for the vehicle,
shorts to “Ignition 1” in the deployment loops, high
resistance or opens in the “Driver Side” and
“Passenger Side” circuits and measures the resistance
of the inflator assembly consisting of 1) Initiators, 2)
SRS coil assembly (driver side only), 3) Connectors
and associated wiring.
Normal Operating Voltage Range
The voltage measured between the SRS control unit
“Ignition 1” terminals and “Ground” terminals is
between 9 and 16 volts.
Passenger Current Source
An output of the SRS control unit which applies current
into the passenger air bag assembly circuit during the
“Initiator Assembly Resistance Test”.
Passenger Air Bag Assembly
An assembly located in the front of the passenger side
of the instrument panel consisting of an inflatable bag,
an inflator and an initiator.
Scan Tool
An external computer used to read diagnostic
information from on–board computers via the data link
connector.
SRS control unit
SRS control unit which provides reserve energy to the
deployment loops, deploys the air bags when required
and performs diagnostic monitoring of all SRS
components.
Serial Data
Information representing the status of the SRS.
SRS
Supplemental Restraint System.
SRS Coil Assembly
An assembly of two current–carrying coils in the driver
deployment loop that allows the rotation of the steering
wheel while maintaining the continuous contact of the
driver deployment loop to the driver air bag assembly.
SRS Wiring Harness
The wires and connectors that electrically connect the
components in the SRS.
“Turn–ON”
Test which the SRS control unit performs on the SRS
once during each ignition cycle immediately after
“Ignition 1” voltage is applied to the SRS control unit
and before “Continuous Monitoring”.
Diagnosis
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS
A
BATTERY–POWERED OR AC–POWERED
V
OLTMETER, OHMMETER, ETC., OR ANY TYPE
OF ELECT RICAL EQ UIPMENT OTHER THAN TH AT
SPECIFIED IN THIS MANUAL. DO NOT USE
A
NONPOWERED PROBE–TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE
PERSONAL INJURY MAY RESULT.
Diagnostic Trouble Codes
The “SRS Diagnostic System Check” must always be
the starting point of any SRS diagnosis. The “SRS
Diagnostic System Check” checks for proper “AIR
BAG” warning lamp operation and checks for SRS
diagnostic trouble codes using the scan tool.
1. Current diagnostic trouble codes – Malfunctions
that are presently being detected. Current
diagnostic trouble codes are stored in RAM
(Random Access Memory).
2. Histor y diagnostic trouble codes – All m alfunctions
detected since the last time the history memor
y
was cleared. History diagnostic trouble codes
are stored in EEPROM.
Scan Tool Diagnostics
A scan tool is used to read current and history
diagnostic trouble codes and to clear all diagnostic
trouble codes after a repair is completed. The scan
tool must be updated to communicate with the SRS
through a replaceable cartridge before it can be used
for SRS diagnostics. To use the scan tool, connect it
to the data link connector and turn the ignition switch
“ON”. The scan tool reads serial data from the SRS
control unit “Serial Data” line terminal “21” to the data
link connector terminal “2”.
Use Of Special Tools
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS
A
BATTERY–POWERED OR AC–POWERED
V
OLTMETER, OHMMETER, ETC, OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A NON
POWERED PROBE–TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE
PERSONAL INJURY MAY RESULT. YOU SHOULD
BE FAMILIAR WITH THE TOOLS LISTED IN THIS
SECTION UNDER THE HANDLING SRS SPECIAL
TOOLS.
You should be able to measure voltage and
resistance. You should be familiar with proper use of
a scan tool such as the Tech 2 Diagnostic Computer,
SRS Driver/Passenger Load Tool 5-8840-2421-0,
Connector Test Adapter Kit 5-8840-0385-0 and the
DVM (Digital Multimeter) 5-8840-0285-0.
SRS Connector Body Face Views
060R300040
Legend
(1) SRS contro l unit
(2) Driv er Air Bag Assembly
(3) Passenger Air Bag Assembly
(4) “Air Bag” Warning Lamp
(5) DLC
Repairs And Inspections Required After An Accident
If any SRS components are damaged, they must be
replaced. If SRS component mounting points are
damaged, they must be replaced.
• Never use SRS parts from another vehicle. This
does not include remanufactured parts purchased
from an authorized dealer; they may be used fo
r
SRS repairs.
• Do not attempt to service the SRS control unit, the
SRS coil assembly, or the air bag assembly.
Service of these items is by replacement only.
• Verify the part number of replacement air bag
assembly.
CAUTION: Never use the air bag assembly from
another vehicle and different model year air bag
assembly.
Only use the air bag assembly suited to the TFR/S
model, which is being repaired.
CAUTION: Proper operation of the sensors and
supplemental restraint system (SRS) requires that
any repairs to the vehicle structure return it to the
original production configuration. Deployment
requires, at a minimum, replacement of the SRS
control unit, air bag assembly and dimensional
inspection of the steering column. Any visible
damage to the SRS control unit mounting bracket
(s) requires replacement, and the steering column
must be dimensionally inspected, whethe
r
deployment occurred or not.
Accident With Deployment – Component
Replacement And Inspections
Certain SRS components must be replaced or
inspected for damage after a frontal crash involving air
bag deployment. Those components are:
• Air bag assembly
• SRS control unit
CAUTION: Refer to “SRS control unit
Replacement Guidelines” below for important
information on SRS control unit replacement in
both deployment and non-deployment crashes.
• SRS coil assembly — Inspect wiring and connecto
r
for any signs of scorching, melting, or damage due
to excessive heat. Replace if damaged. Refer to
section SRS Coil Assembly in this manual.
Accident With or Without Deployment –
Component Inspection
Certain SRS system components and rotating parts
must be inspected after any crash, whether the air
bag deployed or not. Those components are:
• Steering column — Refer to Inspection Required
After an Accident in this manual.
• Knee bolsters and mounting points — Inspect fo
r
any distortion, bending, cracking, or other damage.
• I/P steering column reinforcement plate — Inspect
for any distortion, bending, cracking, or othe
r
damage.
• I/P braces — Inspect for any distortion, bending,
cracking, or other damage.
• Seat belts and mounting points — Refer to
Seat Belts in Section “Seat Belt” of this workshop
manual.
SRS Control Unit Replacement Guidelines
SRS control unit replacement policy requires
replacement of SRS control unit, after a crash
involving air bag deployment when “SRS Warning
Lamp” illuminates, “SRS Diagnosis” should be done
according to Section “Restraint Control System.”
Wiring Damage
If any SRS wiring harness is damaged, it should be
replaced. Don't repair SRS harness. They are to be
replaced.
SRS Connector (Plastic Body And
Terminal Metal Pin) Damage
If any connector or terminal in the SRS wiring harness
(except pigtails) is damaged, they should be replaced.
SRS Wire Pigtail Damage
If the wiring pigtail (a wire or wires attached directly to
the device, not by a connector) is damaged, the entire
component (with pigtail) must be replaced. Examples
of “pigtail” components are the driver air bag
assembly, the passenger air bag assembly, and the
SRS coil assembly.
On–Vehicle Service
Service Precaution
WARNING: WHEN PERFORMING SERVICE ON OR
AROUND SRS COMPONENTS OR SRS WIRING,
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY OR OTHERWISE UNNEEDED SRS
REPAIRS.
The SRS control unit in Driver–Passenger SRS can
maintain sufficient voltage to cause a deployment for
up to 15 seconds after the ignition switch is turned
“OFF,” battery is disconnected, or the fuse powering
the SRS control unit is removed.
Many of the service procedures require removal of the
“SRS” fuse, and disconnection of the air bag
assembly from the deployment loop to avoid an
accidental deployment. If the air bag assembly is
disconnected from the deployment loop as noted in
the “Disabling the SRS” procedure that follows,
service can begin immediately without waiting for the
15 second time period to expire.
Disabling The SRS
Removal
Turn the ignition switch to “LOCK” and remove key.
1. Remove the 10 Amp SRS fuse “SRS”, from the
Cabin Relay and Fuse Box located on the ouside
of the drivers side of the instrument panel o
r
disconnect battery.
2. Disconnect yellow connector at the base o
f
steering column.
3. Remove glove box assembly, refer to Passenge
r
Air Bag Assembly Replacement in this manual.
4. Disconnect yellow connector behind the glove box
assembly.
CAUTION: With the “SRS” fuse removed and
ignition switch “ON”, the “AIR BAG” warning lamp
will be “ON”. This is normal operation and does
not indicate an SRS malfunction.
Enabling The SRS
Installation
CAUTION: Never use the air bag assembly from
another vehicle and different model year air bag
assembly.
Only use the air bag assembly suited to the TFR/S
model, which is being repaired.
Turn ignition switch to “LOCK” and remove key.
1. Connect yellow connector for passenger air bag
assembly.
2. Install glove box assembly. Refer to Passenge
r
air bag assembly replacement in this manual.
3. Connect yellow connector at the base of steering
column.
4. Install 10 Amp SRS fuse “SRS” into the cabin
relay and fuse box, located on the outside of the
drivers side of the instrument panel or reconnect
battery.
Turn ignition switch to “ON” and verify that the “AIR
BAG” warning lamp flashes seven times and then
turns “OFF.” If it does not operate as described,
perform the “SRS Diagnostic System Check” in this
manual.
Handling / Installation / Diagnosis
1. Air bag assembly should not be subjected to
temperatures above 65°C (150°F).
2.
A
ir bag assembly, and SRS control unit should not
be used if they have been dropped from a height
of 100 centimeters (3.28 feet) or more.
3. When a SRS control unit is replaced, it must be
oriented with the arrow on the sensor pointing
toward the front of the vehicle. It is very important
for the SRS control unit to be located flat on the
mounting surface, parallel to the vehicle datum
line. It is important that the SRS control unit
mounting surface is free of any dirt or other foreign
material.
4. Do not apply power to the SRS unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble
code.
5. The “SRS Diagnostic System Check” must be the
starting point of any SRS diagnostics. The “SRS
Diagnostic System Check” will verify proper “AIR
BAG” warning lamp operation and will lead you to
the correct chart to diagnose any SRS
malfunctions. Bypassing these procedures may
result in extended diagnostic time, incorrect
diagnosis, and incorrect parts replacement.
Air Bag Assembly Handling / Shipping / Scrapping
Live (Undeployed) Air Bag Assembly
Special care is necessary when handling and storing a
live (undeployed) air bag assembly. The rapid gas
generation produced during deployment of the air bag
could cause the air bag assembly, or an object in front
of the air bag assembly, to be thrown through the air in
the unlikely event of an accidental deployment.
060R300011
WARNING: WHEN CARRYING A LIVE AIR BAG
A
SSEMBLY, MAKE SURE THE BAG OPENING IS
POINTED AWAY FROM YOU. IN CASE OF AN
A
CCIDENTAL DEPLOYMENT, THE BAG WILL
THEN DEPLOY WITH MINIMAL CHANCE OF
INJURY. NEVER CARRY THE
A
IR BAG
A
SSEMBLY BY THE WIRES OR CONNECTOR ON
THE UNDERSIDE OF THE MODULE.
827RS044
Air Bag Assembly Shipping Procedure
For Live (Undeployed) Air Bag
Assemblies
Service personnel should refer to the latest Service
Bulletins for proper SRS air bag assembly shipping
procedures.
Deployed Air Bag Assembly (Driver Side)
You should wear gloves and safety glasses. After the
air bag assembly has been deployed, the surface of
the air bag may contain a powdery residue. This
powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of the
chemical reaction. Sodium hydroxide dust (similar to
lye soap) is produced as a by product of the
deployment reaction. The sodium hydroxide then
quickly reacts with atmospheric moisture and is
converted to sodium carbonate and sodium
bicarbonate (baking soda). Therefore, it is unlikely
that sodium hydroxide will be present.
Air Bag Assembly Scrapping Procedure
During the course of a vehicle's useful life, certain
situations may arise which will necessitate the disposal
of a live (undeployed) air bag assembly. This
information covers proper procedures for disposing of
a live air bag assembly .
Before a live air bag assembly can be disposed of, it
must be deployed. A live air bag assembly must not
be disposed of through normal refuse channels.
WARNING: FAILURE TO FOLLOW PROPER
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR
BAG ASSEMBLY DISPOSAL PROCEDURES CAN
RESULT IN AIR BAG DEPLOYMENT WHICH MAY
CAUSE PERSONAL INJURY. AN UNDEPLOYED
AIR BAG ASSEMBLY MUST NOT BE DISPOSED
OF THROUGH NORMAL REFUSE CHANNELS.
THE UNDEPLOYED AIR BAG ASSEMBLY
CONTAINS SUBSTANCES THAT CAN CAUSE
SEVERE ILLNESS OR PERSONAL INJURY IF THE
SEALED CONTAINER IS DAMAGED DURING
DISPOSAL. DISPOSAL IN ANY MANNER
INCONSISTENT WITH PROPER PROCEDURES
MAY BE A VIOLATION OF FEDERAL, STATE, AND
/
OR LOCAL LAW.
In situations which require deployment of a live air bag
assembly, deployment may be accomplished inside or
outside the vehicle. The method employed depends
upon the final disposition of the particular vehicle, as
noted in “Deployment Outside Vehicle” and
“Deployment Inside Vehicle” in this section.
Deployment Outside Vehicle (Driver Ai r
Bag Assembly)
Deployment outside the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which the vehicle will be
returned to useful service after a functionally or
cosmetically deficient air bag assembly is replaced.
Deployment and disposal of a malfunctioning air bag
assembly is, of course, subject to any required
retention period.
For deployment of a live (undeployed) air bag
assembly outside the vehicle, the deployment
procedure must be followed exactly. Always wear
safety glasses during this deployment procedure until
a deployed air bag assembly is scrapped or until an
undeployed air bag assembly is shipped. Before
performing the procedures you should be familiar with
servicing the SRS and with proper handling of the air
bag assembly. Procedures should be read fully
before they are performed.
The following procedure requires use of 5-8840-2468-
06 SRS deployment harness with appropriate pigtail
adapter. Do not attempt procedure without 5-8840-
2468-0 adapter.
WARNING: FAILURE TO FOLLOW PROCEDURES
IN THE ORDER LISTED MAY RESULT IN
PERSONAL INJURY. NEVER CONNECT
DEPLOYMENT HARNESS TO ANY POWER
SOURCE BEFORE CONNECTING DEPLOYMENT
HARNESS TO THE DRIVER AIR BAG ASSEMBLY.
DEPLOYMENT HARNESS SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO
A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN
A
POWER SOURCE IS CONNECTED TO IT. WEAR
SAFETY GLASSES THROUGHOUT THIS ENTIRE
DEPLOYMENT AND DISPOSAL PROCEDURE.
NOTE: This information applies only to driver air bag
assembly. Refer to “Deployment Outside Vehicle
(Passenger Air Bag assembly)” in this section fo
r
information on passenger air bag assembly scrapping.
1. Turn ignition switch to “LOCK”, remove key and
put on safety glasses.
2. Inspect 5-8840-2468-0 SRS Deployment Harness
and appropriate pigtail adapter for damage. I
f
harness or pigtail adapter is damaged, dis c ard and
obtain a replacement.
3. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other. SRS deployment harness shall remain
shorted and not be connected to a power source
until the air bag is to be deployed.
827RS004
4. Connect the appropriate pigtail adapter to the SRS
deployment harness.
5. Remove the driver air bag assembly from vehicle.
Refer to “Inflator Module Removal” in this
manual.
WARNING: WHEN STORING A LIVE AIR BAG
A
SSEMBLY OR WHEN LEAVING A LIVE AIR BAG
A
SSEMBLY UNATTENDED ON A BENCH OR
OTHER SURFACE, ALWAYS FACE THE AIR BAG
A
ND TRIM COVER UP AND AWAY FROM THE
SURFACE. THIS IS NECESSARY SO T HAT A FREE
SPACE IS PROVIDED TO ALLOW T HE AIR BAG T O
EXPAND IN THE UNLIKELY EVENT OF
A
CCIDENTAL DEPLOYMENT. FAILURE TO
FOLLOW PROCEDURES MAY RESULT IN
PERSONAL INJURY.
6. Place the driver air bag as sem bly on a work bench
or other surface away from all loose or flammable
objects with its tr im cover f acing up, away from the
surface.
060R300028
7. Clear a space on the ground about 183 cm (six
feet) in diameter where the driver air bag as s embl
y
is to be deployed. A paved, outdoor location
where there is no activity is preferred. If an
outdoor location is not available, a space on the
shop floor where there is no activity and sufficient
ventilation is recommended. Ensure no loose o
r
flammable objects are within the deployment area.
060R300029
8. Place the driver air bag assembly, with its trim
cover facing up, on the ground in the space just
cleared.
9. Stretch the SRS deployment harness and pigtail
adapter from the driver air bag assembly to its full
length.
10. Place a power source near the shorted end of the
SRS deployment harness. Recommended
application: 12 volts minimum, 2 amps minimum.
A vehicle battery is suggested.
11. Connect the driver air bag assembly to the pigtail
adapter on the SRS deployment harness.
Deployment harness shall remain shorted and not
be connected to a power sour ce until the air bag is
to be deployed. The driver air bag assembly will
immediately deploy the air bag when a powe
r
source is connected to it.
NOTE: Ensure that the pigtail adapter is firm ly seated
into the driver air bag assembly connector. Failure to
fully seat the connectors may leave the shorting ba
r
located in the driver air bag assembly connecto
r
functioning (shor ted) and may result in nondeployment
of the driver air bag assembly.
12. Verify that the area around the driver air bag
assembly is clear of all people and loose o
r
flammable objects.
13. Verify that the driver air bag assembly is resting
with its trim cover facing up.
14. Notify all people in the immediate area that you
intend to deploy the driver air bag. The
deployment will be accompanied by a substantial
noise which may startle the uninformed.
15. Separate the two banana plugs on the SRS
deployment harness.
NOTE: When the air bag deploys, the driver air bag
assembly may jump about 30 cm (one foot) vertically.
This is a normal reaction of the driver air bag to the
force of the rapid gas expansion inside the air bag.
NOTE: When the air bag deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the imm ediate area that you intend to deplo
y
the driver air bag.
WARNING: DEPLOYMENT HARNESS SHALL
REMAIN SHORTED AND NOT BE CONNECTED TO
A
POWER SOURCE UNTIL T HE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN
A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
MAY RESULT IN PERSONAL INJURY.
16. Connect the SRS deployment harnes s wires to the
power source to immediately deploy the driver ai
r
bag. Recommended application: 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
17. Disconnect the SRS deployment harness from the
power source.
18. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
19. In the unlikely event that the driver air bag
assembly did not deploy after following these
procedures, proceed immediately with Steps 24
through 26. If 19. the dr iver air bag assem bly did
deploy, proceed with Steps 20 through 23.
20. Put on a pair of shop gloves and safety glasses to
protect your hands and eyes from possible
irritation and heat when handling the deployed
driver air bag ass embly. After the air bag ass embl
y
has been deployed, the surface of the air bag m a
y
contain a powdery residue. This power consists
primarily of cornstarch (used to lubricate the bag
as it inflates) and by products of the chemical
reaction. Sodium hydroxide dust (similar to lye
soap) is produced as a by product of the
deployment reaction. The sodium hydroxide then
quickly reacts with the atmospheric moisture and
is converted to sodium carbonate and sodium
bicarbonate (bak ing s oda). T heref ore, it is unlik el
y
that sodium hydroxide will be present afte
r
deployment.
WARNING: SAFETY PRECAUTIONS MUST BE
OBSERVED WHEN HANDING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE VERY HOT. ALLOW THE INFLATOR
MODULE TO COOL BEFORE HANDLING ANY
METAL PORTION OF IT. DO NOT PLACE THE
DEPLOYED AIR BAG ASSEMBLY NEAR ANY
FLAMMABLE OBJECTS. FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN FIRE OR
PERSONAL INJURY.
AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN
DEPLOYED, THE METAL CANISTER AND
SURROUNDING AREAS OF THE DRIVER AIR BAG
ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH
THE METAL AREAS OF THE DRIVER AIR BAG
ASSEMBLY FOR ABOUT TEN MINUTES AFTER
DEPLOYMENT. IF THE DEPLOYED DRIVER AIR
BAG ASSEMBLY MUST BE MOVED BEFORE IT IS
COOL, WEAR GLOVES AND HANDLE BY THE AIR
BAG OR TRIM COVER.
21. Disconnect the pigtail adapter from the driver ai
r
bag assembly as soon after deployment as
possible. This will prevent damage to the pigtail
adapter or SRS deployment harness due to
possible contact with the hot driver air bag
assembly canister. The pigtail adapter can be
reused. They should, however, be inspected fo
r
damage after each deployment and replaced i
f
necessary .
22. Dispose of the deployed driver air bag assembl
y
through norm al refuse channels after it has cooled
for at least 30 minutes.
23. Wash your hands with mild soap and wate
r
afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the driver air bag assembly did not
deploy after following these procedures.
24. Ensure that the SRS deployment harness has
been disconnected from the power source and that
its two banana plugs have been shorted togethe
r
by fully seating one banana plug into the other.
25. Disconnect the pigtail adapter from the driver ai
r
bag assembly.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE
INFLATOR MODULE UNATTENDED ON A BENCH
OR OTHER SURFACE, ALWAYS FACE THE BAG
AND TRIM COVER UP AND AWAY FROM THE
SURFACE. THIS IS NECESSARY SO THAT
A
FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG TO EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. FAILURE TO
FOLLOW PROCEDURES MAY RESULT IN
PERSONAL INJURY.
26. Temporarily store the driver air bag assembly with
its trim cover facing up, away from the surface
upon which it rests.
Deployment Outside Vehicle (Passenger
Air Bag Assembly)
WARNING: FAILURE TO FOLLOW PROPER SRS
A
IR BAG ASSEMBLY DISPOSAL PROCEDURES
CAN RESULT IN AIR BAG DEPLOYMENT WHICH
MAY CAUSE PERSONAL INJURY. UNDEPLOYED
A
IR BAG ASSEMBLIES MUST NOT BE DISPOSED
OF THROUGH NORMAL REFUSE CHANNELS.
THE UNDEPLOYED AIR BAG ASSEMBLY
CONTAINS SUBSTANCES THAT CAN CAUSE
SEVERE ILLNESS OR PERSONAL INJURY IF THE
SEALED CONTAINER IS DAMAGED DURING
DISPOSAL. DISPOSAL IN ANY MANNER
INCONSISTENT WITH PROPER PROCEDURES
MAY BE A VIOLATION OF FEDERAL, STATE
AND/OR LOCAL LAWS.
Deployment out of the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which a functionally or
cosmetically deficient air bag assembly is replaced.
Deployment and disposal of an air bag assembly is, of
course, subject to any required retention period.
For deployment of a live air bag assembly out of the
vehicle, the deployment procedure must be followed
exactly. Always wear safety glasses during this
deployment procedure until the deployed air bag
assembly is scrapped. Before performing the
procedures, you should be familiar with servicing the
SRS system and with proper handling of the air bag
assembly. Procedures should be read fully before
they are performed.
The following procedure requires use of 5-8840-2468-
0 SRS Deployment Harness with the appropriate
pigtail adapter. The procedure also requires the use
of 5-8840-2420-0 Passenger Side SRS Module
Deployment Fixture. Do not attempt this procedure
without 5-8840-2468-0 and adapter, and
5-8840-2420-0.
WARNING: FAILURE TO FOLLOW PROCEDURES
IN THE ORDER LISTED MAY RESULT IN
PERSONAL INJURY. NEVER CONNECT
DEPLOYMENT HARNESS TO ANY POWER
SOURCE BEFORE CONNECTING DEPLOYMENT
HARNESS TO THE AIR BAG ASSEMBLY.
DEPLOYMENT HARNESS SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO
A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN
A
POWER SOURCE IS CONNECTED TO IT. WEAR
SAFETY GLASSES THROUGHOUT THIS ENTIRE
DEPLOYMENT AND DISPOSAL PROCEDURE.
NOTE: This information applies only to passenger ai
r
bag assembly. Information for disposing of a live
driver air bag assembly can be found in “Deployment
Outside Vehicle” (Driver Air Bag Assembly) in this
section.
1. Turn ignition switch to “LOCK” remove key, and
put on safety glasses.
2. Inspect 5-8840-2468-0 SRS Deployment Harness
and appropriate pigtail adapter for damage. I
f
harness or pigtail is damaged, discard and obtain
a replacement.
3. Short the two SRS Deployment Harness leads
together by fully seating one banana plug into the
other. The SRS Deployment Harness shall
remain shorted and not be connected to a powe
r
source until the air bag is to be deployed.
827RS003
4. Connect the appropriate pigtail adapter to the SRS
Deployment Harness
827RS004
5. Remove passenger air bag assembly from vehicle.
Refer to “Passenger Air Bag
Assembly Removal “.
6. Clear a space on the ground approximately 183
cm (six feet) in diameter where the fixture with
attached air bag assembly is to be placed fo
r
deployment. A paved outdoor location where
there is no activity is preferred. If an outdoo
r
location is not available, a s pace on the s hop floo
r
where is no activity and sufficient ventilation is
recommended. Ensure that no loose o
r
flammable objects are within the deployment area.
7. Place the 5-8840-2420-0 on the bench vice. This
is necessary to provide sufficient stabilization o
f
the fixture during deployment.
8. Attach the passenger air bag assembly in the 5-
8840-2420-0. An air bag assembly must be
mounted such that the bag will deploy upward.
SECURELY HAND–TIGHTEN ALL FASTENERS
PRIOR TO DEPLOYMENT.
901RW199
9. Stretch the SRS Deployment Harness and pigtail
adapter from the air bag assembly to its full
length.
10. Place a power source near the shorted end of the
SRS deployment harness. (Recommended
application: 12 volts minimum, 2 amps minimum.
A vehicle battery is suggested.)
11. Connect the air bag assem bly to the pigtail adapte
r
on the SRS deployment harness. The SRS
Deployment Harness shall rem ain shorted and not
be connected to a power sour ce until the air bag is
to be deployed. The air bag assembly will
immediately deploy the air bag when a powe
r
source is connected to it.
NOTE: Ensure that the pigtail adapter is firmly seated
into the air bag assembly connector. Failure to full
y
seat the connectors may leave the shorting bar located
in the air bag assembly connector f unc tioning ( shor ting
the deployment circuit) and may result in
nondeployment of the air bag assembly.
12. Verify that the area around the passenger air bag
assembly is clear of all people and loose o
r
flammable objects.
13. Verify that the passenger air bag assembly is
firmly and properly in 5-8840-2420-0.
14. Notify all people in the immediate area of you
r
intention to deploy the passenger air bag
assembly. The deployment will be accompanied
by a substantial noise which may startle the
uninformed.
15. Separate the two banana plugs on the SRS
deployment harness.
NOTE: When the air bag deploys, the driver air bag
assembly may jump about 30 cm (one foot) vertically.
This is a normal reaction of the driver air bag to the
force of the rapid gas expansion inside the air bag.
NOTE: When the air bag deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the imm ediate area that you intend to deplo
y
the air bag assembly.
WARNING: DEPLOYMENT HARNESS SHALL
REMAIN SHORTED AND NOT BE CONNECTED TO
A POW ER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN
A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
MAY RESULT IN PERSONAL INJURY.
16. Connect the SRS deployment harnes s wires to the
power source to immediately deploy the air bag
assembly. Recommended application : 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
17. Disconnect the SRS deployment harness from the
power source.
18.Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
19. In the unlikely event that the passenger air bag
assembly did not deploy after following these
procedures, proceed immediately with Steps 24
through 26. If the passenger air bag assembl
y
deployed as intended, proceed with Steps 20
through 23.
20.The passenger inflator requires no special
precaution after deployment. 95% of the
particulate em ission are potassium ckloride ( KLC),
which is commonly sold as an edible salt-
substitutes. even if water is applied. Post
deployment products are relatively pH neutral.
Disposing the inflator by burying it in a landfill will
not produce any hazardous products. As with an
y
dusty environment, safety goggles, dust mask and
gloves should be worn.
WARNING: SAFETY PRECAUTIONS MUST BE
OBSERVED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE HO T. AL LOW THE AIR BAG ASSEMBLY
TO COOL BEFORE HANDLING ANY METAL
PORTIO N O F IT. DO NO T PL ACE THE DEPLOY ED
INFLATOR MODULE NEAR ANY FLAMMABLE
OBJECTS. FAILURE TO FOLLOW PROCEDURES
MAY RESULT IN FIRE OR PERSONAL INJURY.
A
FTER AN AIR BAG ASSEMBLY HAS BEEN
DEPLOYED, THE METAL CANISTER AND
SURROUNDING AREAS OF THE AIR BAG
A
SSEMBLY WILL BE HOT. DO NOT TOUCH THE
METAL AREAS OF THE AIR BAG ASSEMBLY FOR
A
BOUT THIRTY MINUTES AFTER DEPLOYMENT.
IF THE DEPLO YED AIR BAG ASSEM BLY M UST BE
MO VED BEF ORE IT IS COO L, WEAR GLOVES AND
HANDLE BY THE AIR BAG ITSELF.
21. Disconnect the pigtail adapter from the air bag
assem bly as soon after deployment as possible to
avoid damage to the pigtail adapter or SRS
deployment harness from contacting the hot ai
r
bag assembly canister. The pigtail adapter and
SRS deployment harness are designed to be
reused. They should, however, be inspected fo
r
damage after each deployment and replaced i
f
necessary .
22. Dispose of the deployed air bag assem bly through
normal refuse channels after it has cooled for at
least 30 minutes.
23. Wash your hands with mild soap and wate
r
afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the air bag assem bly did not deplo
y
after following the above procedures.
24. Ensure that the SRS deployment harness has
been disconnected from the power source and that
its two banana plugs have been shorted togethe
r
by fully seating one banana plug into the other.
25. Disconnect the pigtail adapter from the air bag
assembly.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENCH OR
OTHER SURFACE, ALWAYS FACE THE BAG UP
AND AWAY FROM THE SURFACE. THIS IS
NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG TO EXPAND
IN THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT. FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN PERSONAL
INJURY.
26. Temporarily store the air bag assembly with the
bag facing up, away from the sur f ac e upon which it
rests.
Deployment Inside Vehicle (Vehicle
Scrapping Procedure)
Deployment inside vehicle is proper when the vehicle
is to be destroyed or salvaged for component parts.
This includes, but is not limited to, the following
situations:
1. The vehicle has completed its useful life.
2. T he vehicle has been damaged beyond repair in a
nondeployment type accident.
3. The vehic le has been s tripped or damaged beyond
repair in a theft.
4. The vehicle will be salvaged for component parts
to be used on a vehicle with a different Vehicle
Identification Number (VIN) as opposed to being
rebuilt as same VIN. Never use SRS components
from another vehicle.
WARNING: FAILURE TO FOLLOW PROPER SRS
AIR BAG ASSEMBLY DISPOSAL PROCEDURES
CAN RESULT IN AIR BAG DEPLOYMENT WHICH
MAY CAUSE PERSONAL INJURY. UNDEPLOYED
AIR BAG ASSEMBLIES MUST NOT BE DISPOSED
OF THROUGH NORMAL REFUSE CHANNELS.
THE UNDEPLOYED AIR BAG ASSEMBLY
CONTAINS SUBSTANCES THAT CAN CAUSE
SEVERE ILLNESS OR PERSONAL INJURY IF THE
SEALED CONTAINER IS DAMAGED DURING
DISPOSAL. DISPOSAL IN ANY MANNER
INCONSISTENT WITH PROPER PROCEDURES
MAY BE A VIOLATION OF FEDERAL, STATE
AND/OR LOCAL LAWS.
1. Turn ignition switch to “LOCK,” remove key and
put on safety glasses.
2. Remove all loose objects from front seats.
3. Disconnect driver air bag assembly, yello
w
connector located at the base of the steering
column.
4. Cut the driver air bag assembly yellow harness
connector from the vehicle leaving at least 15 cm
(six inches) of wire at the connector.
5. Strip 13 mm (1/2 inch) of insulation from yellow –
green and yellow – black wire lead of the
connector.
6. Cut two 900 cm (30 feet) deployment wires from
0.8 mm2 (18 gauge) or thicker multi–strand wire.
These wires will be used to fabricate the drive
r
deployment harness.
7. Strip 13 m m (1/2 inc h) of ins ulation f rom both ends
of the wires cut in the previous step.
8. Short the wires by twisting together one end from
each. Deployment wires shall remain shorted and
not be connected to a power source until the ai
r
bag is to be deployed.
WARNING: FAILURE TO FOLLOW PROCEDURES
IN THE ORDER LISTED COULD RESULT IN
PERSONAL INJURY. NEVER CONNECT
DEPLOYMENT WIRES TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT WIRES TO
THE AIR BAG ASSEMBLY LEAD S. DEPLO YM ENT
WIRES SHALL REMAIN SHORTED AND BE NOT
CONNECTED TO A POWER SOURCE UNTIL THE
A
IR BAG IS TO BE DEPLOYED. THE AIR BAG
A
SSEMBL Y W ILL IM M EDIATELY DEPL OY T HE AIR
BAG WHEN A POWER SOURCE IS CONNECTED
TO IT. WEAR SAFETY GLASSES THROUGHOUT
THIS ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
9. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
10. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate
and secure.
11. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire.
12. Connect the deployment harness to the driver ai
r
bag assembly, yellow connector at the base of the
steering column. Route deployment harness out
the driver side of the vehicle.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO
A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
DEPLOY THE AIR BAG WHEN A POWER SOURCE
IS CONNECTED TO IT.
Connecting the deployment wires to the powe
r
source should always be the final step in the ai
r
bag assembly deployment procedure.
Failure to follow procedures in the order listed
could result in personal injury.
13. Disconnect passenger air bag assembly, yello
w
connector located behind glove box assembly.
14.Cut the passenger air bag assembly harness
connector from the vehicle leaving at least 15 cm
(six inches) of wire at the connector.
15. Strip 13 mm (1/2 inch) of insulation from blue–
white and pink–blue wire lead of the connector.
16. Cut two 900 cm (30 feet) deployment wires from
0.8 mm2 (18 gauge) or thicker multi–strand wire.
These wires will be used to fabricate the
passenger deployment harness.
17. Strip 13 mm ( 1/2 inch) of ins ulation f r om both ends
of the wires cut in the previous step.
18. Short the wires by twisting together one end from
each. Deployment wires shall remain s hor ted and
not be connected to a power source until the ai
r
bag is to be deployed.
WARNING: FAILURE TO FOLLOW PROCEDURES
IN THE ORDER LISTED COULD RESULT IN
PERSONAL INJURY. NEVER CONNECT
DEPLOYMENT WIRES TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT WIRES TO
THE AIR BAG ASSEMBLY LEAD S. DEPLO YM ENT
WIRES SHALL REMAIN SHORTED AND NOT BE
CONNECTED TO A POWER SOURCE UNTIL THE
AIR BAG IS TO BE DEPLOYED. THE AIR BAG
ASSEMBL Y WIL L IM M EDIATELY DEPLO Y T HE AIR
BAG WHEN A POWER SOURCE IS CONNECTED
TO IT. WEAR SAFETY GLASSES THROUGHOUT
THIS ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
19. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
20. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate
and secure.
21. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire.
22. Connect the deployment harnes s to the passenge
r
air bag assem bly, yellow connector loca ted behind
the glove box assembly. Route deployment
harness out the passenger side of the vehicle.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO
A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN
A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT WIRES
SHOULD ALWAYS BE THE FINAL STEP IN THE
AIR BAG ASSEMBLY DEPLO YM ENT PROCEDURE.
FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED COULD RESULT IN PERSONAL
INJURY.
23. Verify that the inside of the vehicle and the area
surrounding the vehicle are clear of all people and
loose or flammable objects.
24. Stretch the driver and passenger deployment
harness to their full length.
25. Completely cover windshield area and front doo
r
window openings with a drop cloth, blanket o
r
similar item. This reduces the possibility of injur
y
due to possible fragmentation of the vehicle's
glass or interior.
26. Notify all people in the immediate area that you
intend to deploy the air bags. T he deployment will
be accompanied by a substantial noise which ma
y
startle the uninformed.
27. Separate the two ends of the driver deployment
harness wires.
WARNING: DEPLOYM ENT WI RES SHALL REM AIN
SHORTED AND NOT BE CONNECTED TO
A
POWER SOURCE UNTIL THE AIR BAG IS TO
A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN
A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT WIRES TO THE
POWER SOURCE SHOULD ALWAYS BE THE
FINAL STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
COULD RESULT IN PERSONAL INJURY.
NOTE: When the air bag deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the imm ediate area that you intend to deplo
y
the air bags.
28. Connect the driver deployment harness wires to a
power source to immediately deploy the driver ai
r
bag assembly. Recommended application: 12
volts minimum, 2 amps minimum. A vehicle
battery is suggested.
29. Separate the two ends of the passenge
r
deployment harness wires.
WARNING: DEPLOYM ENT WI RES SHALL REM AIN
SHORTED AND NOT BE CONNECTED TO
A
POWER SOURCE UNTIL THE AIR BAG IS TO
A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN
A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT WIRES TO THE
POWER SOURCE SHOULD ALWAYS BE THE
FINAL STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
COULD RESULT IN PERSONAL INJURY.
30.Connect the passenger deployment harness wires
to a power source to immediately deploy the
passenger air bag assembly. Recommended
application: 12 volts minimum, 2 amps minimum.
A
vehicle battery is suggested.(Driver air bag
assem bly) Put on a pair of shop gloves and safet
y
glasses to protect your hands and eyes from
possible irritation and heat when handling the
deployed air bag assembly. After an air bag
assembly has been deployed, the surface of the
air bag may contain a powdery residue. This
powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products o
f
the chemical reaction. Sodium hydroxide dust
(similar to 30. lye soap) is produced as a b
y
product of the deployment reaction. The sodium
hydroxide then quickly reacts with atmospheric
moisture and is converted to sodium carbonate
and sodium bicarbonate (baking soda). Therefore,
it is unlikely that sodium hydroxide will be present
after deployment.(Passenger air bag assembly)
The passenger inflator requires no special
precaution after deployment. 95% of the
particulate em ission are potas sium chloride (KLC),
which is commonly sold as an edible salt-
substitutes. even if water is applied. Post
deployment products are relatively pH neutral.
Disposing the inflator by burying it in a landfill will
not products any hazardous products. As with an
y
dusty environment, safety goggles, dust mask and
gloves should be worn.
WARNING: SAFETY PRECAUTIONS MUST BE
OBSERVED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE VERY HOT. ALLOW THE AIR BAG
ASSEMBLY TO COOL BEFORE HANDLING ANY
METAL PORTION OF IT. DO NOT PLACE THE
HOT DEPLOYED AIR BAG ASSEMBLY NEAR ANY
FLAMMABLE OBJECTS. FAILURE TO FOLLOW
PROCEDURES COULD RESULT IN FIRE OR
PERSONAL INJURY.
After an air bag assembly has been deployed, the
metal canister and surrounding areas of the ai
r
bag assembly will be very hot. Do not touch the
metal areas of the air bag assembly for about 30
minutes after deployment. If the deployed air bag
assembly must be moved before it is cool, wea
r
gloves and handle by the air bag or trim cover.
31. Short the driver deployment harness wires b
y
twisting together one end from each. Repeat this
procedure for the passenger deployment harness.
32. Carefully rem ove drop cloth f r om vehic le and clean
off any fragments or discard drop cloth entirely.
33. Disconnect driver deployment harness and
passenger deployment harness from vehicle and
discard.
34.In the unlikely event that either or both of the ai
r
bag assemblies did not deploy after following
these procedur es, proceed im m ediately with Steps
36 through 37. If the air bag assembly deployed,
proceed to step 35.
35. With both air bags deployed, the vehicle may be
scrapped in the same manner as a non–SRS
equipped vehicle.
NOTE: The remaining steps are to be followed in the
unlikely event that the air bag assem bly did not deplo
y
after following these procedures.
36. Rem ove the undeployed air bag assem bly (s) from
the vehicle. For driver air bag assem bly refer to in
the “Drive Air Bag Assembly Removal“ in this
manual. For passenger air bag assembly refer to
in the “Passenger Air Bag Assembly Removal”
in this manual.
WARNING: WHEN STORING A LIVE AIR BAG
A
SSEMBLY OR WHEN LEAVING A LIVE AIR BAG
A
SSEMBLY UNATTENDED ON A BENCH OR
OTHER SURFACE, ALWAYS FACE THE BAG AND
TRIM COVER UP, AWAY FROM THE SURFACE.
THIS IS NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG TO EXPAND
IN THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT. FAILURE TO FOLLOW
PROCEDURES COULD RESULT IN PERSONAL
INJURY.
37. T em porarily store the air bag ass em bly with the ai
r
bag opening facing up, away from the surface
upon which it rests.
Deployed Air Bag Assembly Handling
Put on a pair of shop gloves and safety glasses to
protect your hands and eyes from possible irritation
and heat when handling the deployed air bag
assembly.
After the air bag assembly has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of the
chemical reaction. Sodium hydroxide dust (similar to
lye soap) is produced as a by product of the
deployment reaction. The sodium hydroxide then
quickly reacts with atmospheric moisture and is
converted to sodium carbonate and sodium
bicarbonate (baking soda). Therefore, it is unlikely
that sodium hydroxide will be present after
deployment.
Tech 2 Scan Tool
From 98 MY, Holden dealer service departments are
recommended to use Tech 2. Please refer to Tech 2
scan tool user guide.
901RW200
Legent
(1) PCMCIA Card
(2) RS 232 Loop Back Connector
(3) SAE 16/19 Adaptor
(4) DLC Cable
(5) Tech-2
Getting Started
• Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. Insert the Isuzu System PCMCIA card (1) into the
Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
3. Connect the DLC cable to the Tech 2 (5)
4. Make sure of the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the
vehicle DLC connector.
060R300015
6. Turn on the vehicle ignition switch.
7. Verify the Tech 2 power up display.
060RW009
NOTE:The RS232 Loop back connector is only used
to diagnosis Tech 2. Refer to user guide of the Tech 2.
Service Precautions for SRS Component Service
CAUTION: When fasteners are removed, always
reinstall them at the same location from which
they were removed. If a fastener needs to be
replaced, use the correct part number fastener fo
r
that application. If the correct part numbe
r
fastener is not available, a fastener of equal size
and strength (or stronger) may be used. fasteners
that are not reused, and those requiring thread
locking compound will be called out. The correct
torque value must be used when installing
fasteners that require it. If the above conditions
are not followed, parts or system damage could
result.
WARNING: WHEN PERFORMING SERVICE O N OR
A
ROUND SRS COMPONENTS OR SRS WIRING,
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY OR OTHERWISE UNNEEDED SRS
REPAIRS.
The SRS control unit in Driver–Passenger SRS can
maintain sufficient voltage to cause a deployment for
up to 15 seconds after the ignition switch is turned
“OFF,” the battery is disconnected, or the fuse
powering the SRS control unit is removed.
Many of the service procedures require removal of the
“SRS” fuse, and disconnection of the air bag assembly
from the deployment loop to avoid an accidental
deployment. If the air bag assembly is disconnected
from the deployment loop as noted in the “Disabling
the SRS” procedure that follows, service can begin
immediately without waiting for the 15 second time
period to expire.
Disabling The SRS
Removal
Turn the ignition switch to “OFF” and turn the steering
wheel so that the vehicle's wheels are pointing straight
ahead.
1. Rem ove SRS fuse “ SRS” f rom left dash side lowe
r
fuse block or disconnect battery.
2. Disconnect yellow connector at the base o
f
steering column.
3. Remove glove box assembly; Refer to “Passenge
r
air bag assembly replacement” in this section.
4. Disconnect passenger air bag assembly yello
w
connector behind the glove box assembly.
CAUTION: With the “SRS” fuse removed and
ignition switch “ON,” the “AIR BAG” warning lamp
will be “ON.” This is normal operation and does
not indicate an SRS malfunction.
Enabling The SRS
Installation
Turn ignition switch to “LOCK” and remove key.
1. Connect yellow connector passenger air bag
assembly.
2. Install glove box assembly. Refer to “Passenge
r
Air Bag Assembly Replacement” in this section.
3. Connect yellow connector at the base of the
steering column.
4. Install “AIR BAG” fuse “SRS” to left dash side
lower fuse block or connect battery.
Turn ignition switch to “ON” and verify that the “AIR
BAG” warning lamp flashes seven times and then
turns “OFF.” If it does not operate as described,
perform the “SRS Diagnostic System Check” in this
section.
Handling / Installation / Diagnosis
1.
A
ir bag assembly should not be subjected to
temperatures above 65°C (150°F).
2.
A
ir bag assem bly, and SRS control unit should not
be used if they have been dropped from a height
of 100 centimeters (3.28 feet) or more.
3. When a SRS control unit is replaced, it must be
oriented with the arrow on the SRS control unit
pointing toward the front of the vehicle. It is ver
y
impor tant for the SRS control unit to be located flat
on the mounting surface, parallel to the vehicle
datum line. It is impor tant that the SRS control unit
mounting s ur f ac e is free of any dir t or other f or eign
material.
4. Do not apply power to the SRS unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble
code.
5. The “SRS Diagnostic System Check” must be the
starting point of any SRS diagnostics. The “SRS
Diagnostic System Check” will verify proper “AIR
BAG” warning lamp operation and will lead you to
the correct chart to diagnose any SRS
malfunctions. Bypassing these procedures ma
y
result in extended diagnostic time, incorrect
diagnosis, and incorrect parts replacements.
Inspections Required After An Accident
CAUTION: Certain SRS components must be
replaced after a frontal crash involving air bag
deployment.
In all types of accidents regardless of “Air Bag”
deployment, visually inspect all of the following
components and replace as required:
– Driver air bag assembly
– Passenger air bag assembly
– Steering wheel
– SRS coil assembly
– Steering column
– Knee bolster and instrument panel mounting
attachments
– Driver seat and belt
– Passenger seat and belt
– SRS control unit
SRS control unit always should be checked according
to “SRS Control Unit Replacement Guidelines.”
CAUTION: Refer to “ SRS control unit Replacement
Guidelines” below for important information on
SRS control unit replacement in both deployment
and non–deployment crashes.
Inspect SRS coil assembly wiring and steering wheel
for any sign of scorching, melting, or damage due to
excessive heat. If coil assembly wire or steering wheel
is damaged, replace them. The steering column and
wheel must be dimensionally checked to determine if
they are damaged. Refer to steering wheel of in this
manual.
Never use SRS parts from another vehicle. This does
not include remanufactured parts purchased from an
authorized Isuzu Retailer; they may be used for SRS
repairs.
Do not attempt to repair the SRS control unit, the SRS
harness, the SRS coil assembly, the air bag assembly,
the steering wheel, or the steering column. Service of
these items is replacement only. Verify replacement
part numbers.
CAUTION: Proper operation of the SRS control
unit and supplemental restraint system (SRS)
requires that any repairs to the vehicle structure
return it to its or iginal production configuration.
SRS Connectors
CAUTION: T he special yellow color co nnecto rs are
used for supplemental restraint system-air bag
circuit. When removing the cable harness, do not
pull the cables otherwise, cable disconnection
may occur. When connect the SRS connector,
insert the connector completely. Imperfect locking
may c ause malfunction of S RS circuit.
Installation
To install the connector, hold the socket insulator (1)
and insert it. The cover insulator slides and connector
will be locked. Do not hold the cover insulator (2).
827RW027
Removal
To remove the connector, hold the cover insulator (1)
and pull it. The cover insulator slides and lock will be
released. Do not hold the socket insulator (2).
827RW028
SRS Control Unit
5. Rem ove the three SRS control unit f ixing bolts and
remove SRS control unit.
060R300008
Legent
(1) SRS contro l unit
(2) SRS Harness
(3) Connector Position Assurance
Service Precautions
WARNING: DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING SRS control
unit. NEVER STRIKE OR JAR SRS control unit.
UNDER SOME CIRCUMSTANCES, IT COULD
CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY OR IMPROPER OPERATION
OF THE SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) . SRS control unit MOUNTING BRACKET
BOLTS MUST BE CAREFULLY TORQUED TO
A
SSURE PROPER OPERATION. NEVER POWER
UP THE SRS WHEN SRS control unit IS NOT
RIGIDLY ATTACHED TO THE VEHICLE. THE SRS
control unit COULD BE ACTIVATED WHEN
POWERED WHILE NOT RIGIDLY ATTACHED TO
THE VEHICLE WHICH COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL
INJURY.
WARNING: PROPER OPERATION OF THE SRS
CONTROL UNIT REQUIRES THE SRS CONTROL
UNIT TO BE RIGIDLY ATTACHED TO THE
V
EHICLE STRUCTURE AND THAT THE ARROW
ON THE SENSOR BE POINTING TOWARD THE
FRONT OF THE VEHICLE.
SRS control unit is specifically calibrated and is keyed
to the SRS control unit location SRS wiring harness.
Caution should be used to ensure proper location of
the SRS control unit. The keying of the SRS control
unit to its location and wiring harness connectors
should never be modified in the field.
Removal
1. Dis able the SRS (Refer to “Disabling the SRS” in
this section).
2. Remove the transmission knob (for M/T) and
transfer lever knob.
3. Remove the front console assembly and
disconnect wiring harness connector.
4. Pull CPA (Connector Position Assurance) out and
push connector lock down to disconnect the SRS
control unit harness connector.
Installation
1. Install the SRS control unit on bracket and fixing
bolts and tighten the fixing bolts to the specified
torque.
Torque: 7 ±
±±
± 2 N⋅
⋅⋅⋅m (0.7 ±
±±
± 0.2 kg⋅
⋅⋅⋅m/61 lb in)
2. Connect the SRS control unit harness connecto
r
and after that, put CPA into connector.
3. Install the front console.
4. Install the transm ission k nob (f or M/T ) and tr ansfe
r
lever knob.
Driver Air Bag Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWER ON THE AIR BAG
ASSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY,
AND WASH YOUR HANDS WITH MILD SOAP AND
WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOYMENT,
THE BAG WILL THEN DEPLOY WITH MINIMAL
CHANCE OF INJURY. WHEN PLACING ALIVE AIR
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE BAG AND TRIM
COVER UP, AWAY FROM THE SURFACE. NEVER
REST A STEERING COLUMN ASSEMBLY ON THE
STEERING WHEEL WITH THE AIR BAG
ASSEMBLY FACE DOWN AND COLUMN
V
ERTICAL. THIS IS NECESSARY SO THAT A
FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKEL
Y
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD
RESULT.
NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting
or any other damage due to excessive heat. If the coil
has been damaged, replace it.
Removal
1. Disable the SRS (Refer to Disabling the SRS in
this section).
2. Locate both side holes in the steering cover.
060R300025
3. Locate the position of the pins in a hole. Push the
pins in the direction of the arrow.
060R300032
4. Push the four pins with a 5∼6 mm bar.
060R300045
5. Remove the SRS air bag.
NOTE: Care should be taken not to damage SRS air
bag connector harness when removing SRS air bag.
. 6. Disconnect the SRS air bag connector pin.
060R300042
7. Disconnect the SRS air bag connector and horn
lead connector located behind the air bag
assembly and remove the air bag assembly.
060R300041
Installation
1. Connect the SRS air bag connector and horn lead
connector.
060R300041
2. Connect the SRS air bag connector pin.
060R300042
3. Align each snap stud of driver air bag with the
holes of steering wheel.
060R300030
060R300020
4. Push the SRS air bag assembly at AREA 1 and
A
REA 2. At the same time confirm that an audible
noise of each stud locating can be heard.
060R300036
5. Enable the SRS (Refer to Enabling the SRS in
this section).
CAUTION: Never use the air bag assembly from
another vehicle and different model year air bag
assembly.
Only use the air bag assembly suited to the TFR/S
model, which is being repaired.
Steering Wheel
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN
A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWER ON THE AIR BAG
A
SSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY,
A
ND WASH YOUR HANDS WITH MILD SOAP AND
WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
A
SSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOYMENT,
THE BAG WILL THEN DEPLOY WITH MINIMAL
CHANCE OF INJURY. WHEN PLACING ALIVE AIR
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE BAG AND RIM COVER
UP, AWAY FROM THE SURFACE. NEVER REST
A
STEERING COLUMN ASSEMBLY ON THE
STEERING WHEEL WITH THE AIR BAG
A
SSEMBLY FACE DOWN AND COLUMN
V
ERTICAL. THIS IS NECESSARY SO T HAT A FREE
SPACE IS PROVIDED TO ALLOW THE AIR BAG
ASSEMBLY T O EXPAND IN THE UNLIKELY EVENT
OF ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY COULD RESULT.
In the event deployment has occurred, inspect coil
assembly wire for any signs of scorching, melting o
r
any other damage due to excessive heat. If the coil
has been damaged, replace it.
Removal
1. Remove the SRS air bag assembly. (Refer to
“Driver Air Bag Assembly” in this section)
2. Remove steering wheel attachment nut.
3.
A
pply a setting mark across the steering wheel
and shaft so parts can be reassembled in thei
r
original position.
060R300024
4. Move the tires to the straight ahead pos ition bef ore
rem oving the steering wheel. Install st eering wheel
puller onto steering wheel and remove steering
wheel with 5-8521-0016-0.
060R300009
5. Feed wiring through the wheel and remove wheel.
CAUTION: Never apply force t o the steering w heel
in direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as
an energy absorbing unit.
Installation
1. Install the steering wheel and align the setting
marks.
060R300024
NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.
RTW33BSH000601
2. Tighten the steering wheel fixing nut to the
specified torque.
Torque : 34 Nm (3.5 kgm/25 lb ft)
3. Install the SRS air bag as sem bly. (Refer to “ Drive
r
Air Bag Assembly” in this section)
SRS Coil Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWER ON THE AIR BAG
ASSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY,
AND WASH YOUR HANDS WITH MILD SOAP AND
WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOYMENT,
THE BAG WILL THEN DEPLOY WITH MINIMAL
CHANCE OF INJURY. WHEN PLACING ALIVE AIR
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE BAG AND RIM COVER
UP, AWAY FROM THE SURFACE. NEVER REST A
STEERING COLUMN ASSEMBLY ON THE
STEERING WHEEL WITH THE AIR BAG
ASSEMBLY FACE DOWN AND COLUMN
V
ERTICAL. THIS IS NECESSARY SO THAT A
FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKEL
Y
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD
RESULT.
NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting
or any other damage due to excessive heat. If the coil
has been damaged, replace it.
Removal
1. Remove the SRS air bag assembly. (Refer to
Driver Air Bag Assembly in this seciton)
2. Remove the steering wheel attachment nut.
060R300009
3.
A
pply a setting mark across the steering wheel
and shaft so parts can be reassembled in thei
r
original position.
060R300024
4. Move the front wheels to the straight ahead
position before removing the steering wheel and
remove wheel with 5-8521-0016-0.
5. Feed wiring harness through the steering wheel
and remove steering wheel.
6. Remove the steering lower cover and engine hood
opening lever.
7. Remove the driver knee bolster assembly.
8. Remove the steering column cover.
9. Remove air conditioning lower duct.
10.Disconnect the wiring harness connectors located
at the base of steering column.
CAUTION: Never apply force to the steering wheel
in the direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as
an energy absorbing unit.
11. Remove the combination switch and SRS coil
assembly.
NOTE: SRS coil is part of the combination switch
assembly, and cannot be serviced separately.
Therefore, be sure not to remove the SRS coil from
the combination switch assembly.
Installation
1. Install the combination switch and SRS coil
assembly.
2. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark.
CAUTION: When turning the SRS coil
counterclockw ise to full, stop turning if resistance
is felt. Further forced turning may cause damage
to the cable in the SRS coil.
826RW014
Legend
(1) Neutral mark
3. Connect the wiring harness connectors located at
the base of steering column.
4. Install the air conditioning lower duct.
5. Install the steering column cover.
CAUTION: When installing the steering column
cover, be sure to route wiring harness as
illustrated, so that the starter switch, combination
switch and SRS coil harness will not be damaged.
825RS048
6. Install the driver knee bolster assembly.
7. Install the steering lower cover and engine hood
opening lever.
8. Install the steering wheel and align the setting
marks.
060R300024
Steering Column
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWER ON THE AIR BAG
ASSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY,
AND WASH YOUR HANDS WITH MILD SOAP AND
WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOYMENT,
THE BAG WILL THEN DEPLOY WITH MINIMAL
CHANCE OF INJURY. WHEN PLACING ALIVE AIR
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE BAG AND RIM COVER
UP, AWAY FROM THE SURFACE. NEVER REST A
STEERING COLUMN ASSEMBLY ON THE
STEERING WHEEL WITH THE AIR BAG
ASSEMBLY FACE DOWN AND COLUMN
V
ERTICAL. THIS IS NECESSARY SO THAT A
FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKEL
Y
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD
RESULT.
In the event deployment has occurred, inspect coil
assembly wire for any signs of scorching, melting o
r
any other damage due to excessive heat. If the coil
has been damaged, replace it.
Removal
1. Remove the SRS air bag assembly. (Refer to
Driver Air Bag Assembly in this section)
2. Remove the steering wheel attachment nut.
060R300009
3.
A
pply a setting mark across the steering wheel
and shaft so parts can be reassembled in thei
r
original position.
060R300024
4. Move the tires to the straight ahead position
before removing the steering wheel and removing
wheel with 5-8521-0016-0.
5. Feed wiring though the steering wheel and
remove steering wheel.
6. Remove the steering lower cover and engine hood
opening lever.
7. Remove the driver knee bolster assembly.
RTW39JSH000101
8. Remove the steering column cover.
9. Disconnect the wiring harness connectors located
at the base of steering column.
CAUTION: Never apply force to the steering wheel
in the direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as
an energy absorbing unit.
10. Remove the combination switch assembly with
SRS coil.
SRS coil is a part of combination switch assembly,
which cannot be replaced separately. Therefore, be
sure not to remove the SRS coil from the combination
switch assembly.
11.Remove the snap ring.
12. Remove the cushion rubber.
13. Disconnect shift lock cable (A/T only).
14.Disconnect the starter switch harness connecto
r
located base of steering column.
15. Remove steering lock cylinder assembly.
16.
A
pply a setting mark across the universal joint and
steering shaft to reassemble the parts in thei
r
original position.
060R300038
17.Remove steering column assembly.
Installation
1. Install the steering column assembly and align the
setting marks on the universal joint and steering
shaft made during removal.
060R300038
2. Tighten the steering column fixing bolts (dash
panel side) to the specified torque.
Torque: 20 Nm (2.0 kgm/14 lb ft)
3. Tighten the steering column fixing bolts (Pedal
bracket) to the specified torque.
Torque: 20 Nm (2.0 kgm/14 lb ft)
4. Tighten the universal joint to the specified torque.
Torque: 31 Nm (3.2 kgm/23 lb ft)
5. Install steering lock cylinder assembly.
6. Connect shift lock cable (For A/T)
7. Install cushion rubber.
8. Install snap ring.
9. Install the combination switch assembly with SRS
coil.
10. Connect the wiring harness connector located on
the base of steering column.
11. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark.
CAUTION: When turning the SRS coil
counterclockw ise to full, stop turning if resistance
is felt. Further forced turning may cause damage
to the cable in the SRS coil.
826RW014
Legend
(1) Neutral mark
12.Install steering column cover.
CAUTION: When installing the steering column
cover, be sure to route wiring harness as
illustrated, so that the starter switch, combination
switch and SRS coil harness will not be damaged.
825RS048
13.Install the steering wheel and align the setting
marks.
Passenger Air Bag Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN
A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWER ON THE AIR BAG
A
SSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY,
A
ND WASH YOUR HANDS WITH MILD SOAP AND
WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
A
SSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOYMENT,
THE BAG WILL THEN DEPLOY WITH MINIMAL
CHANCE OF INJURY. WHEN PLACING ALIVE AIR
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE BAG AND RIM COVER
UP, AWAY FROM THE SURFACE. NEVER REST
A
STEERING COLUMN ASSEMBLY ON THE
STEERING WHEEL WITH THE AIR BAG
A
SSEMBLY FACE DOWN AND COLUMN
V
ERTICAL. THIS IS NECESSARY SO T HAT A FREE
SPACE IS PROVIDED TO ALLOW THE AIR BAG
A
SSEMBL Y T O EXPAND IN THE UNLIKEL Y EVENT
OF ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY COULD RESULT.
WARNING: IN THE EVENT DEPLO
Y
MENT HAS
OCCURRED, INSPECT COIL ASSEMBLY WIRE
FOR ANY SIGNS OF SCORCHING, MELTING OR
ANY OTHER DAMAGE DUE TO EXCESSIVE HEAT.
IF THE COIL HAS BEEN DAMAGED, REPLACE IT.
Removal
1. Disable the SRS. (Refer to “Disabling the SRS”
in this section)
2. Remove glove box.
3. Remove glove box cover.
4. Remove passenger air bag assembly fixing bolts
and nuts. Universal joint is used when removing a
nut.
060R300043
060R300044
5. Remove passenger air bag assembly.
6. Disconnect passenger air bag assembly harness
connector.
Installation
1. Connect passenger air bag assembly harness
connector.
2. Install passenger air bag assembly.
3. Install passenger air bag ass embly fixing bolts and
nuts. Universal joint is used when removing a nut.
Torque: 8 Nm (0.8 kgm/78 lb in)
060R300043
060R300044
4. Install glove box cover.
5. Install glove box.
6. Enable the SRS. (Refer to “Enabling the SRS” in
this section)
Main Data and Specifications
Fastener Tightening Specification
Application Nm kgm Lb Ft (Lb in)
SRS control unit 10 1.0 7
Steering wheel fixing bolt 34 3.5 25
Steering column (dash panel side fixing bolts) 20 2.0 14
Steering column (Pedal bracket fixing bolt) 20 2.0 14
Steering column (Universal joint fixing bolt) 31 3.2 23
Passenger Air Bag fixing bolt & nut 8 0.8 (78)
Special Tools
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS
A
BATTERY–POWERED OR AC–POWERED
V
OLTMETER, OHMMETER, ETC., OR ANY TYPE
OF ELECT RICAL EQ UIPMENT OTHER THAN TH AT
SPECIFIED IN THIS MANUAL. DO NOT USE
A
NONPOWERED PROBE–TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE
PERSONAL INJURY MAY RESULT.
5-8840-2421-0 SRS Driver/Passenger Load Tool
901RS146
The SRS Driver/Passenger Load Tool 5-8840-2421-0
is used only when called for in this section. It is used
as a diagnostic aid and safety device to prevent
inadvertent air bag assembly deployment.
The load tool has three yellow connectors attached to
its case.
The three small connectors are electrically functional
and serve as resistive load substitutions.
No more than two connectors are used at any time.
One of the small connectors is used to substitute for
the load of the driver air bag assembly when it is
connected at the top of the column to the SRS coil
assembly. Another small connector is used to
substitute for the load of the driver air bag assembly
and the SRS coil assembly when it is connected at the
base of the column to the SRS wiring harness. The
third small connector is used to substitute for the load
of the passenger air bag assembly when connected to
the passenger air bag assembly harness connector.
By substituting the resistance of the load tool when
called for, a determination can be made as to whether
an inflator circuit component is causing system
malfunction and which component is causing the
malfunction. The load tool should be used only when
specifically called for in the diagnostic procedures.
5-8840-0285-0 DVM
901RS163
The 5-8840-0285-0 DVM is the preferred DVM for use
in SRS diagnosis and repair. However, 5-8840-0366-
0 may be used if 5-8840-0285-0 is not available. No
other DVMs are approved for SRS diagnosis and
repair.
Scan Tool
901RW176
The Tech 2 is used to read and clear SRS Diagnostic
Trouble Codes (DTCs). Refer to the Tech 2
Operators, Manual for specific information on how to
use the Tech 2.
5-8840-0385-0 Connector Test Adapter Kit
901RS151
The 5-8840-0385-0 Connector Test Adapter Kit must
be used whenever a diagnostic procedure requests
checking or probing a terminal. Using the appropriate
adapter will ensure that no damage to the terminal will
occur from the DVM prove, such as spreading or
bending. The adapter will also give an idea of
whether contact tension is sufficient, helping to find an
open or intermittent open due to poor terminal contact.
5-8840-2468-0 SRS Deployment Tool
901RW106
The 5-8840-2468-0 SRS Deployment Tool must be
used for deployment of the undeployed air bag.
5-8840-2420-0 SRS Deployment Fixture
901RV056
The 5-8840-2420-0 SRS Deployment Fixture must be
used for deployment of the undeployed passenger
side air bag.
5-8840-2796-0 SRS Adapter for Load Tool
901RW107
The 5-8840-2796-0 SRS Adapter for Load Tool must
be used with 5-8840-2421-0 SRS Driver/Passenger
Load Tool.
5-8840-2795-0 SRS Adapter for Deployment Tool
901RW107
The 5-8840-2795-0 SRS Adapter for Deployment Tool
must be used with 5-8840-2468-0 SRS Deployment
Tool.
5-8521-0016-0 Steering Wheel remover
LNW28BSH003101